1 Safety valve 2. Output steam control valve 3. Feed water tank overflow 4. Feed water tank ball valve 5. Feed water tank drain 6. Housing cover plate 7. Boiler drain valve 8. Power supply inlet 9. Water supply inlet 10. Feed water tank 11. Frost protection water drain
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Boiler rear elevation
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Boiler front inner elevation
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1. Electric control panel 2. Live, neutral & earth terminals 3. Electric leakage protection 4. Feed water pump fuse 5. Heating elements contactor 6. Feed water pump air bleed 7. Feed water pump 8. Heating elements fuse 9. Steam heating elements 10. Check valve stops reverse flow 11. Feed water pump motor
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Right side boiler elevation
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Boiler view from above
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1. Product rating plate 2. Feed water level sensor 3. Glass level tube with valves 4. Glass tube with flushing valve 5. Feed water levelling pipe
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1. High/low levelling of feed water 2. Low level limit stops heating 3. On/off pressure control 4. Pressure gauge 5. Pressure sensing pipe 6. Robust earth connection
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Connect water supply, insert an isolating valve; ensure feed water is blow 50°C We recommend the installation of a water-softening plant.
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Connect the steam boiler output through a non-return valve to a distribution system
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Connect 3 x L’s to three live supply wires 1 x N to neutral supply 1 x PE to robust earth
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Connect safety valve outlet and frost valve outlet to sump. Avoid scalding of installer and operators on these pipe runs
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Check that the feed water tank is clean and free of all debris. Open valve and allow water into the Feed Water tank. Flow will stop when the tank is full and the ball valve is satisfied.
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Open the steam valve and close the drain outlet valve. Purge all air from the steam drum
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Open air screw on the feed water pump and check all air is removed. Switch on pump for 60 seconds and repeat air test until only water appears
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Switch on the power supply and the controller lights up. Check all terminals
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Press the ‘POWER’ button Full screen lights up Boiler indicates ‘lack of water’
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Press ‘ON/OFF’ button Feed water added automatically And the high water mark reached and the feed water pump stopped plus the pump symbol disappears. Water is entering the steam drum If the feed water tank remains full, the Pump may be jammed – press ‘+’ for more than 5 seconds otherwise repeat the exercise of step three.
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Press ‘ON/OFF’ on controller Boiler is in ‘RUN’ condition and everything will operate. Display ‘P-L’, boiler will commence heating – turn on steam valve and cycle of heat/water feed will proceed
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IMPORTANT NOTICE Boilers (3kW-15kW) have only one heating tube The remainder have two tubes, used in alternative lead order Symbols on the controller ‘M’ water level between ‘H’ and ‘L’ ‘L’ feed water pump on ‘H’ feed water pump off
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Open the steam valve slowly to encourage dry steam at stable pressure To stop the boiler 1. Press ‘POWER’ button – controller display disappears 2. Turn of main electrical power 3. After 15seconds and pressure drops to 1BARg, open drain outlet
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WARNING Do not open the drain immediately after stopping the boiler 1. Boiler can be damaged 2. Potential scalding of people close by
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Setting the time control
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The steam boiler must be under the control of a qualified operator The operator must be in attendance during time setting
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Regular Maintenace
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After boiler is switched off, allowed to cool for 15minutes, and pressure falls to 1BARg Then drain valve is opened to release condensate
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do not open drain valve too soon – there will be damage to the boiler
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Daily Maintenance
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Monthly Safety Valve Test
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Under pressure conditions, manually test the safety valve handle for blow-down conditions
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If there is no blow-down, replace or service the safety valve
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Monthly Electrical Terminals Check
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Turn off the main power supply – check all terminal screws and bolts
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Three Monthly check heating tubes and boiler for scale
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The heating tubes need to be withdrawn and, together with the boiler shell, cleaned of scale The amount of water treatment can be adjusted a s the amount of scale is recorded
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Fault Finding
ERROR POSSIBLE FAULT LIKELY REPAIR
LCD controller – no display Fuse failure Change fuse
Low voltage Check voltage
Wire(s) loose Check circuits
LCD faulty Replace LCD
LCD lights up – button F no go High or low voltage Check voltage
Button F faulty Replace LCD
Feed water pump not operating Pump seized Press ‘+’ to rotate pump
at low water boiler conditions No LCD message Replace LCD
Fuse burnt out Replace fuse
Wiring loose Check connections
Pump burnt out Replace pump
Pump rotating, no water flow Air in the pump Release the air
Check valve blocked Clean check valve
Water pump jammed Switch off boiler/open housing/release jamming
Water pump impeller worn Replace pump
Feed water full, pump continues Scale on high level water probe Check the HL water probe & clean if possible
HL probe connection loose Check the HL probe circuit
Water level control not correct Check the HL/LL control levels
Heat Contactor operates Circuit breaker not operating Open the circuit breaker
reduced or no output Circuit breaker has failed Replace the circuit breaker
AC contactor has failed Replace the AC contactor
Heating tube has failed Replace the heating tube
Power circuit has failed Fit new power wiring
Water level sensor failure Build-up of scale on sensor Clean or replace sensor
Water overspill from boiler Ball valve blocked in open tank Open tank lid and repair
Ball valve broken Replace ball valve
Open tank filled with hot water Back-feed from check valve Clean or replace check valve
Circuit breaker fails in OFF position Reset button in ‘OFF’ position Press re-set button
Heating tube has failed Replace heating tube
Circuit breaker has failed Replace circuit breaker
Circuit breaker circuit is faulty Check the circuit
Boiler over-rides working pressure Pressure controller faulty Replace pressure controller
Pressure control circuit faulty Check the circuit
Safety valve exhausts at low setting Safety valve is at faulty setting Test for behaviouror safety valve has alternate faulty steam/water cycle Safety valve has failed Replace with certificated safety valve
Safety valve exhausts too much water Incorrect action of feed water pump Drain boiler of water & re-start cycle
Water level sensor over-cycling Clean & wash the water level sensor